Process control system and configuration system

ABSTRACT

A configuration system for a process control system configured to perform process control. The configuration system includes, not limited to, a) a definition module, which is stored in a memory, for a part of an industrial plant based on design data. The definition module includes, not limited to, a-1) a control logic definition file configured to define a control logic for the part, and a-2) a data definition file configured to define data relating to the defined control logic.

FIELD OF INVENTION

This disclosure of invention relates to the field of industrialautomation for an industrial plant. In particular, it relates toconfiguration of process control systems for the industrial plant.

BACKGROUND

FIG. 1A illustrates a process control system 100 of an industrial plantfor oil, steel and chemical process industries. In the industrial plant,field devices such as sensors 102 and valve devices, actuators 104measure or control processes such as fluid process performed by plantequipment. Examples of sensors 102 are flowmeters, temperatureindicators, valve devices 104 are flow amount control valves andopen/close valves, actuators 104 are fans and motors. The field devices102, 104 are connected to a field network 106. The field devices 102,104 are connected through input-output (I/O) units to controllers 108which are in a control network 110. Based on measurements from thesensors 102, the controllers 108 perform computations which are used togenerate signals to control the actuators. Each control logic in thecontroller 108 is encapsulated in a function block. The function blockis defined to receive or generate input, output parameters defined foreach field device and include algorithms to calculate the parameters.Parameters include process variables and tuning parameters which aregenerated in the function block. Process variable is variable for whicha measurement exists, such as temperature, pressure, force, feed, flowrate, chemical composition, weight, position and speed. Tuning parameteris a variable applied in the controller to control the processes.Control logic is an algorithm of the controllers 108.

Human machine interface (HMI) terminals 112 in the control network 110,exchange data with the function blocks and provide information tooperators for operating the process control system 100. The processcontrol system 100 manages and issues commands, from the functionblocks, for parts such as equipment and field devices based on theexchanged data. The issued commands are based on control logic which isprepared and modified in an engineering tool 120 according to designdata, which is a specification of the industrial plant. The controllogic is converted to binary control data for execution in thecontrollers and HMI terminals. The operators control and operate theindustrial plant by applying the binary control data in the controllersand HMI terminals. The HMI terminals 112 screen definitions are preparedby the engineering tool 120. The function blocks, based on themeasurements from the sensors and binary control data, performcomputation to generate signals for the actuators. The operators set adesign value for the tuning parameters during process tuning.

FIG. 1B illustrates the engineering tool 120 for setting or configuringthe process control system 100. Users use an editor 122 in theengineering tool 120 to prepare and modify the control logic for anychange in the design data of the industrial plant. Example of a changeis to set a different field device parameter value for a differentprocess or a different raw material for the process. The differentprocess is for a different product or a different grade of a sameproduct. The prepared and modified control logic is stored as serializedcontrol data 124. The serialized control data 124 is read by a converter126. The converter 126 generates, from the serialized control data 124,binary control data 128 which is control data in binary format. Thebinary control data 128 is stored in a database 130. The binary controldata 128 is sent to process control system 100 for execution in the HMIterminals 112 and controllers 108.

In the industrial plant, there are many data files and data sets for theparameters. The parameters have complex data relationships when relateddata sets are of different type or source. An example is a parameter ina function block related to a controller. The parameter is defined as afirst type in the function block and defined as a second type when in analarm management system. The first type and second type of definitionsare different. It is tedious to identify corresponding parameters to beupdated in the control logic for the process control system 100 when aparameter or parameter relationship is changed in the design data.

Documents, such as instruction manuals, control logic definitions, andspecifications, for the industrial plant are prepared manually as shownin FIG. 1C, using a tool which is separate and different from theengineering tool. The documents for the process plant, from the controllogic to the control data, are prepared independently.

Since the documents are prepared manually, it is tedious andtime-consuming to ensure that the documents are consistent with thecontrol logic or control data for the industrial plant. In an example ofan oil process plant, composition of raw materials such as oil dependson country of origin. Therefore, control logic in process control systemof the process plant has to be changed for each different composition.Documents for the different control logic for the different compositionof raw materials are manually prepared individually. The preparation istedious and time consuming.

The documents are prepared by a user, who is either a customer or avendor, of the engineering tool or process control system. As differentusers prepare and modify the control logic differently, the documentsmust be prepared or updated by the same user. This is inconvenient andcumbersome to other users.

Further, the control logic is changed continuously due to continuousoperational improvements in the industrial plant. In an ideal situation,the documents are updated for every change in the control logic.However, in reality, it is logistically challenging to update thedocuments every time there is a change in the control logic. Therefore,the documents are usually not updated. In some cases, users consolidatechanges in the control logic to update the documents periodically.Mistakes and oversights are common occurrences during the preparation orupdate of the documents, since documentation is a manual process. Theperiodic update can cause more inaccuracies. This results ininconsistency between the control logic and the documents. When thedocuments lack accuracy, the documents are not reliable documentationfor the process plant.

In a typical industrial plant, a specification document consists ofthousands of pages. It is tedious and time-consuming to update such ahuge document manually. In order to ensure that the documents areconsistent with the control logic, a lot of additional man-effort, timeand cost are required for the manual process. This increases the cost tomaintain and update the process control systems. In addition to the costof maintenance and update of the control logic, an additional cost isrequired to ensure that the documentation is consistent with the controllogic, when a change is required for the process control system. In acost competitive environment for process industries, the cost tomaintain documentation is put off or avoided completely. In thesesituations, the documents are obsolete from a lack of update. There is aneed to improve the preparation and update of the documents.

Industrial plants are designed and built to last for a long period of 30years or more. In a typical large scale industrial plant, the processcontrol system controls more than 10,000 field devices. There are manycomplex and advanced functions in the process control system. For anindustrial plant which has many complex and advance functions, manyusers are required to work together to maintain or update control logicof the plant control system. The users would have been changed over theyears of plant operation. Existing users have to refresh theirunderstanding on the control logic, and new users have to find out andunderstand the control logic, in order to make changes to the controllogic. One way to understand the control logic is from the documents. Itis not possible to understand from the documents when the documents areinconsistent with the control logic due to the reasons explained above.

There are many engineering tasks to prepare a process control system.One engineering task is a method of generating the control logic or thedocument. Tests are performed on the generated control logic to ensurethat the control logic is correct. Engineering tasks, design, generationand testing of control logic, are performed repetitively since thecontrol logic includes data specific to each controller 108. Thisrequires a lot of effort and time to prepare the process control system100 for the industrial plant.

Different users perform engineering tasks differently. More effort isrequired from the user who does the maintenance when the user isdifferent from a previous user. There is a need to improve andstandardize the quality of engineering tasks. This is to improve theease of understanding the process control system of the process plant.

The users have to spend additional man-effort and time to decipher thecontrol logic and verify using different types of document, such asspecification documents with all revision changes. This incursadditional cost for the maintenance of the process control system.

There is a need to improve the efficiency to prepare, modify andmaintain a process control system and its documentation by reduction ofthe man-effort, time and cost involved. Further, the consistency of thecontrol logic and the documentation needs to be improved. There needs tobe a mechanism to enable continuous maintenance and operationalimprovements efficiently.

SUMMARY

A configuration system for a process control system configured toperform process control. The configuration system includes, not limitedto, a) a definition module, which is stored in a memory, for a part ofan industrial plant based on design data. The definition moduleincludes, not limited to, a-1) a control logic definition fileconfigured to define a control logic for the part, and a-2) a datadefinition file configured to define data relating to the definedcontrol logic.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A is a process control configuration system in a related art.

FIG. 1B is a diagram of an engineering tool in a related art.

FIG. 1C shows a manual workflow to prepare plant documents in a relatedart.

FIG. 2A is a piping and instrumentation diagram of an example processcontrol.

FIGS. 2B and 2C are examples of allocating control logic to controllersaccording to some embodiments of the invention.

FIGS. 3A, 3B, 3C illustrate a definition module according to someembodiments of the invention.

FIG. 4A illustrates an example editor 400.

FIG. 4B illustrates an example of generated links between a definitionmodule and application modules; and defined links between applicationmodules and controllers.

FIG. 5 illustrates an example block diagram of the invention accordingto some embodiments.

FIGS. 6A, 6B, 6C, 6D are workflows according to some embodiments of theinvention.

FIG. 7A is an example display screen for a module generator according tosome embodiments of the invention.

FIG. 7B is an example display screen to display a generated linkaccording to some embodiments of the invention.

FIG. 7C is an example display screen for a document layout configuratoraccording to some embodiments of the invention.

FIG. 7D is an example contents table of a plant document according tosome embodiments.

FIG. 8A is a workflow of an editor according to some embodiments of theinvention.

FIG. 8B is a workflow of a mass editor according to some embodiments ofthe invention.

FIG. 9 is a process control configuration system according to someembodiments of the invention.

FIG. 10 is a block diagram for a process control configuration system.

DETAILED DESCRIPTION

Process Control System

FIG. 2A is a diagram of an example process control system 200 forequipment 210 in an industrial plant 230 (not shown). In the example,the equipment 210 is a crude oil furnace. The process control system 200has parts 220, 222, 224, 226, 228 to control different parts of theequipment 210. The parts 220, 222, 224, 226, 228, each consists ofsub-parts. In the example, the part 220 has sub-parts, field devices202, 204 and control logic 206. The control logic 206 is performed in acontroller 212 (illustrated in FIG. 9) for controlling a process 232(not shown) in the industrial plant 230. In this example the controllogic 206 is for controlling the field devices 202, 204 according todesign data 234 (not shown) for the industrial plant 230.

In this example, field device 202 is a sensor, an input device whichsends an input parameter to the controller 212. The controller 212 hascontrol logic 206 in two function blocks, a first function block 205 anda second function block 207. The function blocks 205, 207 are softwarecomponents in the controller 212 for processing the control logic 206.The input parameter is processed in the first function block 205 priorto being processed in the second function block 207 to generate anoutput parameter. The controller 212 then transmits the output parameterfrom the second function block 207 to field device 204, an output devicewhich is an actuator to a valve in this example. In this example, thefield devices 202, 204 are connected to a hardware interface component,such as an input-output (I/O) card or module, which is then connected tothe first function block 205 and second function block 207 in thecontroller.

A process control system 200 for the industrial plant 230 consists of aplurality of process control systems 200 for same or different types ofequipment 210 according to some embodiments of the invention.

The process control system 200 includes a plurality of processers and aplurality of HMI terminals 218 (not shown). Each HMI terminal 218consists of a HMI screen 217 (not shown) and an input device. The HMIscreen 217 displays the part 220 and accordingly for the sub-parts,field devices 202, 204. The HMI screen 217 displays all the parts 220,222, 224, 226, 228 and their sub-parts, the field devices 202, 204, thecontrol logic 206 according to some embodiments of the invention.

The process 232 includes, not limited to, a process in the equipment 210and a process in each part 220, 222, 224, 226, 228. Alternatively, theequipment 210 is a part which consists of parts 220, 222, 224, 226, 228.In this alternative, the process in the equipment 210 consists ofprocesses in parts 220, 222, 224, 226, 228.

Parts

The term “part” in the context of the phrase “part of an industrialplant” means “not whole”, one of pieces which constitute an industrialplant. The term “part” in the context of the phrase a process controltarget as a part of the industrial plant means a target which is subjectto the process control performed by the process control system. The“part” or the “process control target” can be hardware alone, softwarealone or the both in combination. Some illustrative examples of the“part” or the “process control target” may include, but are not limitedto, a field device, function blocks, connector, controller, HMI screen.The term “part-related data” means data related to the part or the“process control target” mentioned above. If in a case the “part” is afield device”, then the part-related data means a set of data which isrelated to the field device.

For an industrial plant 230 considered as a whole, a division of thewhole industrial plant 230 is referred to as a part. In the presentinvention, part is a component or an area of the industrial plant 230.Components include, not limited to, field devices 202, 204 such assensors and actuators, control logic 206, controllers 212 and equipment210. The controllers 212 include function blocks 205, 207, connector 209between related function blocks 205, 207 according to some embodimentsof the invention. The part consists of a plurality of sub-parts when thecomponent is made up of other components. For example, a part 220 is anassembly from very basic blocks such as function blocks 205, 207 andconnector 209 for the function blocks 205, 207.

Usually the industrial plant 230 is virtually divided into differentareas for management. For example, area is a collection of componentsfor a particular process, or a collection of components in a physicallocation. The area is further divided into a cell, a unit for ease ofidentification, reference or configuration.

For a graphical user interface considered as a whole, a component whichis used to configure for the graphical user interface to be shown on aHMI screen is referred to as a part. For example part is a data accesspart such as numeric data part, bar graph part, text part, image part.In another example, part is a non data access part such as label partand link part.

Part includes at least one input parameter and one output parameteraccording to some embodiments of the invention. One of the inputparameter or output parameter is fixed and cannot be manipulatedaccording to some embodiments of the invention.

A process control system element means a part, but not whole, of aprocess control system.

Design Data

Design data 234, which is design specifications for the industrial plant230, include data for configuration of a process control system 200 forprocess 232. Design data 234 include data for components such as fielddevices 202, 204, control logic 206, equipment 210, controller 212,function blocks 205, 207, connector 209 and data specific to eachcomponent.

Definition Module

A process control system 200 and its configuration system include aplurality of hardware and software components. A definition module 300is an additional software component which resides on a memory. Thedefinition module 300 is suitable to be used in the process controlsystem 200. The definition module 300 is suitable to be used in theconfiguration system for the process control system 200 according tosome embodiments of the invention. Alternatively, an application module440, which is an instance of the definition module 300, is a softwarecomponent on a memory. The application module 400 is a softwarecomponent of at least one of the process control system 200 and theconfiguration system of the process control system 200.

FIG. 3A illustrates a definition module 300 according to someembodiments of the invention. The definition module 300 is defined torepresent the part 220 of the process control system 200 in theindustrial plant 230.

Alternatively, FIG. 3B further illustrates definition modules 302, 304,306 for sub-parts, the field devices 202, 204 and the control logic 206respectively. In this alternative, the definition module 300 consists ofthe definition modules 302, 304, 306 according to some embodiments ofthe invention. The definition module 306 is defined for control logic206. The control logic 206 consists of function blocks 205, 207, andconnection 209 between function blocks 205, 207. Function blocks 205,207 are further defined in separate definition modules according to someembodiments of the invention.

FIG. 3C illustrates the definition module 300 according to someembodiments of the invention. The definition module 300 includes one ofa property file 310, a control logic file definition 320 and a datadefinition file 330. The definition module 300 further includes aplurality of the control logic definition files 320, a plurality of datadefinition files 330 according to some embodiments of the invention. Theplurality of each type of file, control logic definition file 320 anddata definition file 330, are stored in separate definition filesaccording to some embodiments of the invention.

The definition module 300 is configured based on the design data 234related to part 220. The definition module 300 is reusable for similarparts 222, 224, 226, 228 in the same or different industrial plant 230.This reduces unnecessary repetitive tasks to define a similar definitionmodule 300 for different parts 222, 224, 226, 228.

The definition module 300 is configured based on type of part accordingto some embodiments of the invention. In an example, the definitionmodule 300 is configured for a generic part based on generic design data234. The generic design data 234, which has no restriction, isindependent of the process control system 200. The definition module 300is then defined for the part 220 by being updated with the design data234 for the part 220. An example is instantiating the definition module300 with design data 234 for the part 220.

Advantageously, the definition module 300 is generated with the genericdesign data 234 and is updated with actual design data 234 at a latertime. This improves convenience of configuration for the process controlsystem 200.

Property File

The property file 310 includes module properties of the definitionmodule 300. The property file 310 is used to search and identify usersand usage of the definition module 300. Examples of the properties arean identifier which is unique for the definition module 300, accesspermission which is required for modification of the definition module300, at least one keyword to facilitate an external search of thedefinition module 300 and a last modified date to act as a reference toindicate a recent update or to schedule a next maintenance.

Additional properties which are added to the property file 310 of thedefinition module 300 include information which is related to the part220. Examples of information which are added to the property file 310are HMI screen 217 settings for operation and monitoring HMI terminals218 of the part 220; control logic information such as source code,version, size, timestamp; firmware version, settings, revision history,physical location of the part 220; network information such as media,speed, hardware and software interface settings, external connectionterminals, firewall information of the part 220; logical and physicalconnection information of the part 220; simulation model which the part220 uses; plant information such as version number of piping andinstrumentation diagram, process flow diagram for the part 220.

There is a plurality of property files 310 for the definition module 300according to some embodiments of the invention. Each of the plurality ofproperty files 310 is for a different property to improve the ease ofpreparation of the definition module 300 when the part 220 is modified.

In an example, a HMI screen 217 is displayed on one or more HMIterminals 218 for the part 220 and accordingly for the sub-part fielddevice 202. There are multiple HMI screens 217 displayed on HMIterminals 218 when the HMI screen 217 varies with process conditions oruser preferences for the part 220. Each HMI screen 217 setting for eachvariation of HMI screen 217 is in a separate property file 310. Thisimproves the ease of determining whether the HMI screen 217 is relatedto process conditions or user preference for the part 220.

Control Logic Definition File

The control logic definition file 320 includes one of a control logicdefinition 322, an alarm definition 326 for the part 220. Control logicdefinition 322 consists of control logic 206, which is a processalgorithm for input-output (I/O) signals. Input signal from the fielddevice 202 is defined to be applied to the control logic definition 322for the control logic 206, which is defined to generate an output signalto the field device 204. Examples of I/O signals are process variables,such as values received from the sensor 202 and values transmitted tocontrol valve 204. Process variable is variable for which a measurementexists, such as temperature, pressure, force, feed, flow rate, chemicalcomposition, weight, position and speed.

An additional control logic definition 322, is included in the controllogic definition file 320, when the control logic 206 is available orimported from an external source. This is convenient to include controllogic definition 322 in any format which is imported to the definitionmodule 300.

The control logic definition file 320 includes an alarm definition 326file for the part 220 according to some embodiments. Similarly, alarmdefinition 326 consists of alarm control logic or algorithms forinput-output (I/O) signals from the sub-parts, field devices 202, 204.For example, an alarm is activated based on the input signal from thefield device 202 or output signal to the field device 204, such as theI/O signals being out of a predefined range. The definition module 300is further improved to provide alarm management functions without usinganother alarm notification tool. Resources to configure and maintain theprocess control system 200 with alarm management function furtherimproves consistency with design data 234 compared with using a separateindependent alarm management tool.

In addition to the control logic definition 322, parameter setting 324(not shown) values for sub-parts, the field devices 202, 204 are definedin the control logic definition file 320, and alarm setting 325 values(not shown) in the alarm definition file. The parameter setting 324values include, not limited to, tag name, tag comment, range.

Tuning Parameters

The process algorithm in the control logic definition 322 furtherincludes tuning parameters. Tuning parameter is a variable generated andapplied in the control logic 206 to control the process 232. Using anexample of a proportional-integral-derivative (PID) controller which hasthe following generic algorithm for control logic:

${u(t)} = {{K_{p}{e(t)}} + {K_{i}{\int_{0}^{t}{{e(\tau)}d\;\tau}}} + {K_{d}\frac{d}{d\; t}{e(t)}}}$

-   -   where        -   K_(p): Proportional gain, a tuning parameter        -   K_(i): Integral gain, a tuning parameter        -   K_(d): Derivative gain, a tuning parameter        -   e: Error=Set Point−Process Variable        -   t: Time or instantaneous time (the present)        -   T: Variable of integration; takes on values from time 0 to            the present t

In the above control logic for the PID controller, K_(p), K_(i), K_(d)are examples of tuning parameters. A person skilled in the field ofprocess control systems understands that there are other tuningparameters generated in a function block which is processing the controllogic.

Tuning parameter includes alarm setpoint. The alarm setpoint is a tuningparameter defined in the alarm definition 326 for alarm management inthe process control system 200.

An example use of the tuning parameters is for tuning the process 232when the definition module 300 is used for a first time. The tuningparameter, a function block data item, is generated in function blocks205, 207 of the control logic 206. Thus, the tuning parameter is onlyavailable when the process control system 200 is in operation. Whentuning parameters are required for the first tuning, default values oruser input values are used.

During configuration of the definition module 300, a fixed value isdefined in the control logic 206 for the part 220 to realize a requiredspecific function. The fixed value is a design value, an initial valueor a user-defined value according to some embodiments of the invention.An example use of the fixed value is during a runtime, which isexecution, of the process control system 200. The fixed value isassigned during the tuning phase of the control logic 206.

During an operation of the process control system 200, a current valuewhich is generated in the function block is retrieved for comparisonwith the fixed value. The comparison is used to monitor or control theprocess 232. This improves efficiency of user during operations andsetting the process control system 200 when the tuning parameter, afixed value, is provided with the definition module 300. There is noneed to rely on experience of the user, or look up a reference sourcefor the fixed value. In addition, the current value generated in thefunction block is stored as an updated fixed value when the currentvalue is determined to be a preferred value for tuning the control logic206.

A converter tool such as a generation manager 500 converts the controllogic definition 322 in the definition module 300 to control program orcontrol data 510. Control data 510 is transmitted or loaded tocontrollers 212 in the process control system 200 and is different fordifferent processes 232 or industrial plants 230. The controller 212,executes the control data 510, which reads the definitions to controlthe industrial plant 230.

In an example, a control logic definition file 320 is configured for thepart 220. Control logic 206 for the controller 212 is encapsulated infunction blocks 205, 207. The controller 212 reads the control logic 206in the control data 510, identifies an input process variable, performsthe algorithms in function blocks 205, 207 to generate an output processvariable, and identifies a destination for the output process variable.Examples of the destination are another controller, a field device. Insome examples, the control logic 206 receives input parameters, such asprocess variables from the field device 202 or user input from HMIterminal 218, to be applied to the process algorithm for processing andgenerate an output parameter to control the field device 204. In someexamples, the control logic 206 has the predefined input parameters.Behavior of the field device 204 is dependent on the input parametersand the process algorithm.

The definition module 300 which has control logic 206 configured for theparts 220, 222, 224, 226, 228 being independent on the physical bindingor assignment of the control logic 206 for the parts 220, 222, 224, 226,228 to the controller 212. Using examples in FIGS. 2B and 2C forexplanation, control logic 206, of parts 220, 222, 224, 226, 228, aredefined in a controller 212 identified as “FCS0101” in the definitionmodule 300. In a first assignment in FIG. 2B, the control logic 206 forparts 220, 222, 224, 226, 228 are assigned to a controller 212“FCS0101”. In an alternative second assignment in FIG. 2C, control logic206 for parts 220, 222, 224 are assigned to the first controller 212“FCS0101” and parts 226, 228 control logic 206 to a second controller213 (not shown) “FCS0102”. The control logic 206 in parts 220, 222, 224,226, 228 are valid for both types of assignment.

The control logic definition file 320 includes any one of: control logicdefinitions 322, alarm definitions 326, parameter settings 324 and alarmsettings 325 for the part 220, the sub-parts the field devices 202, 204,the control logic 206, according to some embodiments of the invention.In an example embodiment of a part 220 which includes a network device208 (not shown), such as router, hub or switch, the control logicdefinitions 322, alarm definitions 326, parameter settings 324 or alarmsettings 325 for the network device 208 are included.

A typical industrial plant 230 consists of field devices 202, 204 whichare provided by different vendors. The control logic definitions 322,alarm definitions 326 are prepared in a vendor-specific format for thepart 220 and sub-parts, field devices 202, 204. Alternatively, thecontrol logic definition 322 is prepared in a generic format based on anindustrial standard.

The control logic definition file 320 refers to a location in thedefinition module 300 for storage of contents described above when thecontrol logic definition file 320 is a folder according to someembodiments of the invention.

Data Definition File

The data definition file 330 stores design data 234 which relates to thecontrol logic definition 322 for the part 220. The control logicdefinition 322 is updated when the design data 234 is updated. Thisensures that the control data 510 executed for the process 232 isconsistent with the design data 234.

Rule Definition File

The data definition file 330 includes a rule definition 328 fileaccording to some embodiments of the invention. The rule definition 328is applied to update or change parameter setting 324 values for the part220 or other parts, the field devices 202, 204. The parameter setting324 values in the control logic definition 322 are changed according tochanges in referenced data related to the design data 234. Referenceddata is user configured and editable data, such as from customers,vendors, specific to a particular equipment, process or product. Thereferenced data is configuration or settings data for field devices, orin control logic definitions 322, alarm definitions 326.

The rule definition 328 includes at least one condition and one actionfor setting a parameter in the referenced data to the control logicparameter, when the condition is fulfilled. An example of a rule:control logic parameter “param01” setting for field device is “5” whencorresponding configuration “config_value” setting for field device inreferenced data is “1”.

The referenced data is in a data source according to some embodiments ofthe invention. The term “data source” means one or more sets of data, arepository or a database stored in a memory or a storage configured tostore those data non-transitory. The data source is a combination ofhardware such as a memory or a storage with one or more sets of datasuch as a repository or a database according to some embodiments of theinvention. An example of the data source is an input-output (I/O) listin a file structure stored in a memory which is same or separate fromthe definition module 300. An example of I/O list includes all fielddevices 202, 204 and their properties and parameters. The I/O list isupdated periodically when there is a change in the parameter. The ruledefinition 328 updates the parameter change in the definition module300.

Access rights to edit the rule definition 328 file is restricted toexperienced or authorized users, such as developers or designers of thedefinition module 300. Other users have access rights to view and usethe rule definition 328. This is to minimize errors or inconsistenciesbetween the control logic definition 322 defined for the part 220 andthe design data 234 designed for the part 220. The rule definition 328file is in the control logic definition file 320 according to someembodiments of the invention. This improves the ease of setting accessrights to view and use, without rights to edit, the rule definition 328file when the rule definition 328 file is in the control logicdefinition file 320.

The rule definition 328 interprets and provides complex relationships ofparameters in the design data 234. Consistency of the definition module300 with the design data 234 is improved when the rule definition 328 isincluded in the definition module 300.

The rule definition 328 file includes a plurality of rule definitions328 according to some embodiments of the invention. The rule definitions328 include an option property for the user to select or deselect therule definition 328 for each control logic definition or parameteraccording to some embodiments of the invention. The rule definitions 328further include a rank property to define a priority sequence for therule definitions 328. This further improves the consistency with thedesign data 234.

The rule definition 328 being included in the definition module 300 ismore convenient and efficient compared to a conventional system toinclude a link in an object with control logic to an external ruledatabase. Further, the maintenance and visibility of the complexparameter relationships are improved compared to the conventional systemin which both the link and the external rule database have to bemaintained to ensure consistency with the design data 234.

Document Definition File 331

The data definition file 330 includes a document definition file 331(not shown) which stores document data 332 according to some embodimentsof the invention. The document data 332 includes design data 234 whichis required to generate plant documents 530. The document data 332 isnot used during implementation, such as parameter setting 324, alarmsetting 325, for direct settings or configuration in part 220, sub-partsthe field devices 202, 204, the control logic 206, the function blocks205, 207, connector 209, the network device 208, The document data 332includes test procedure or test data for the definition module 300according to some embodiments of the invention. The document data 332 isused to generate plant documents 530 such as industrial plant 230specifications, instruction manual, control logic definitions 322specifications, alarm definitions 326 specifications and any suchdocument related to the industrial plant 230. The document data 332includes, not limited to, test function data, actual or representativeimages of HMI screen 217, actual or representative images of part 220,subparts the field devices 202, 204, the control logic 206, the networkdevice 208, and any other information. Other information includes a textfile or a video which is an explanation or illustration of theindustrial plant 230 or control logic definition 322.

Plant documents 530 are generated from the document definition file 331are updated to be consistent with the control logic definitions 322, inprocess control system 200 since the definitions are based on the samesource, the design data 234.

There is a plurality of document definition files 331 for the definitionmodule 300 according to some embodiments of the invention. Each of theplurality of document definition files 331 is for a different type ofthe document data 332. For example, each document definition file 331 isprepared separately for each control logic definition 322, alarmdefinition 326, rule definition 328 when there is a plurality of controllogic definitions 322, alarm definitions 326, rule definitions 328 inthe definition module 300. This improves the ease of preparation of theplant document 530 when the different types of the document data 332 areprepared in a plurality of document files 331. Further, this improves anease of maintenance for the document files 331.

Each document definition file 331 consists of documents files, such aslayout file 334, paragraph file 336, section file 338, according to someembodiments of the invention. The layout file 334 defines an arrangementand management of document data 332 which is used to generate a specificplant document 530. The paragraph file 336 is a management of thedocument data 332 by preparing one paragraph for each data portion ornarration of the data portion. For example, one paragraph of documentdata 332 is stored in one text file. Accordingly, the layout file 334defines the layout of a plurality of paragraph files 336 when there ismore than one paragraph file 336. The layout file 334 and the paragraphfile 336 are combined in one narrative document file according to someembodiments of the invention. However, an ease of management and use isimproved when the layout file 334 and the paragraph files 336 aremanaged in separate document files.

Section file 338 is a definition of the document data 332, in text orimages, for a section, a sub-section or a chapter which is a collectionof sections, sub-sections.

Further, the document data 332 includes attachments according to someembodiments of the invention. Examples of attachments are documents ordata which are used generate plant documents 530 or to be included withcontrol data 510. The attachments are stored individually orcollectively in an attachment file 340 as document data 332 consists oftext and images. The attachment file 340 consists of a document file,attachment list file 342 to manage a plurality of attachments, which areused or attached in plant documents 530 in the definition module 300,when there is more than one such file to be attached. The plurality ofsuch files to be attached is listed in the attachment list file 342.

Based on the types of document data 332 available, document definitionfiles 331, attachment files 340 are structured or configured to improvethe ease and efficiency of managing the document data 332 for generatingthe plant documents 530. Different users can update the document data332 and generate any type of plant documents 530 when the designdocument 332 is arranged in the structured document definition files331, attachment files 340.

The document definition file 331 refers to a location in the definitionmodule 300 for storage of contents described above when the documentdefinition file 331 is a folder according to some embodiments of theinvention.

Repository

The definition module 300, the control logic definition files 320, alarmdefinition 326 files, data definition files 330, rule definition 328files, document definition files 331 are stored in a repository 1300after configuration for retrieval to be reused or updated for the samepart 220 or different parts 222, 224, 226, 228. The repository 1300 ison the same computer as an editor tool for the definition module 300.The repository 1300 is located on a secured location, such as a separateserver, computing cloud according to some embodiments of the invention.This allows the repository 1300 to be securely available to more users.Users access the repository 1300. This reduces unnecessary repetitivetasks to define similar control logic 212 for different parts 222, 224,226, 228. The task to define is a control logic 212 is done only once inthe definition module 300 for the equipment 210, instead of five times.

The repository 1300 includes a repository tool to manage contents in therepository 1300. The repository tool has assignment function to assignglobal properties to the contents such as a global identifier and arevision number, in particular the definition modules 300 andapplication modules 440. The definition modules 300 and applicationmodules 440 include a license mark property for the assignment functionto assign a license mark when the module has been licensed to users.

The repository tool includes internal data used to manage contents inthe repository. The internal data includes user information such asaccess rights to browse, search, upload, download and generate reports,licensed contents, files, search function to index browse and search.The internal data includes usage information for the contents, such asusage statistics, usage history for example last user, last download.

Based on global properties such as revision number and internal datasuch as user licensed contents, the repository tool includes anotification function to send notifications to user when there is achange in a global property. In an example, the notification functionsends updated contents to a licensed user when a new revision isavailable.

Based on the global properties and internal data, a user such as acustomer of the repository 1300 can browse to identify useful contentsfor configuration or set up of the process control system 200.

Utilization of accumulated skills and experience to prepare the contentsin the repository 1300 are maximized when the contents are uploaded tobe accessible by multiple users. Resources are to prepare or modify aprocess control system 200 are minimized when users download thecontents from the repository 1300.

Concept of Implementation

The present invention is implemented in an editor tool 400 using anobject oriented programming concept. The definition module 300 is aparent class when it is a base module. A child definition module is achild class when the child definition module inherits the parentdefinition module 300. Changes in the parent class are automaticallyupdated in child class. Thus, the child definition module does notrequire a corresponding manual update when the parent definition module300 is changed, since the child definition module is updatedautomatically.

The definition module 300 is applied to parts 222, 224, 226, 228 sincethe parts are similar to part 220. From FIG. 2A, the same definitionmodule 300 is applied to the parts 220, 222, 224, 226, 228 since theparts 220, 222, 224, 226, 228 have 2 inputs. Further, a definitionmodule 301 (not shown) is prepared for the equipment 210. The definitionmodule 301 consists of five definition modules 300 according to someembodiments of the invention. The definition module 301 has multiplenesting levels when the definition modules 300 further includedefinition modules 302, 304, 306 for sub-parts 202, 204, 206.

An application module 440 is an instance of the definition module 300for part 220 according to some embodiments of the invention. Theapplication module 440 is generated or instantiated when the definitionmodule 300 is assigned specific parameters based on the design data 300or a data source. Accordingly, application modules 442, 444, 446, 448are instances for respective parts 222, 224, 226, 228. The applicationmodule 440 is an instantiated object according to some embodiments ofthe invention.

Using an example to explain, the definition module 300 has genericinformation such as generic control logic. In this example, the genericcontrol logic can be used for any control logic by including specificvalues during an instantiation. The definition module with genericcontrol logic is similar to a template. The application module 440 is aninstantiated definition module 300, which means the control logic in theapplication module 400 has specific values. The application module 440is no longer a template since it has specific values. The control logicin the application module 440 is for a specific part, not for a genericpart. Parameters or data in the control logic of the application module440 have been updated based on the data defined in the data definitionfile 330. In the application module 440, the data definition file 330 isthe same as that in definition module 300.

Advantageously, this invention requires configuration of only onedefinition module 300, instead of five definition modules to be used forthe equipment 210 according to some embodiments of the invention. Thus,the definition module 300 is re-used for other similar parts. Thisimproves efficiency during preparation, maintenance and update of thedefinition modules 300 for the equipment 210 which includes parts 220,222, 224, 226 228.

All application modules 440, 442, 444, 446, 448 are updated when aparameter change in the design data 234 is updated in the definition300. Efficiency of configuration and setting a process control system200 is improved with this invention.

Editor Tool 400

FIG. 4A illustrates an example editor tool 400 in a process controlconfiguration system 900 in FIG. 9 and FIG. 5 illustrates an exampleblock diagram of the editor tool 400 configured to be used for a processcontrol system 200. The editor tool 400 is used to prepare, maintain andmodify the definition module 300 based on design specifications 234 ofthe process control system 200 for industrial plant 230, process 232 orequipment 210. The prepared definition module 300 is stored in a modulelibrary 432 of a database 430. The database 430 is separate from theeditor tool 400 according to some embodiments of the invention. In theseembodiments, the editor tool 400 is configured to communicate with therepository 1300 which includes the database 430.

Computation Control Component 410

The editor tool 400 includes a computation control component 410. Thecomputation control component 410 resides in a processor 1100 of asystem 1000 according to some embodiments of the invention. Thecomputation control component 410 controls all other components in theeditor tool 400 to manipulate the definition module 300 and applicationmodule 440. The manipulation includes preparation, maintenance,modification and instantiation of the definition module 300 to generatean application module 440, and modification of the application module440.

Module Generation Component 412

The editor tool 400 includes a module generation component 412. Themodule generation component 412 is configured to perform one or morefunctions described below. FIG. 6A is a workflow 610 for a function togenerate an application module 440. In S612, the module generationcomponent 412 retrieves the definition module 300 which is stored in themodule library 432.

In S614, the module generation component 412 reads input, such as userinput or input signals received from an input device 1200. The input isa data source according to some embodiments of the invention. The ruledefinition 328 in the definition module 300 defines data sourceparameters as input based on the design data 234.

In S616, the module generation component 412, based on the input and thedefinition module 300, generates or updates the definition module 300.The module generation component 412 generates or instantiates anapplication module 440 according to some embodiments of the invention.

FIG. 7A illustrates an example display screen 450, in the editor tool400, of a generated definition module 300. The definition module 300 andits control logic definition files 320, document definition file 331,attachment file 340 are displayed in a module library window 452. Theproperty file 310 is displayed in the same module library window 452 orin a separate module property file window 454 according to someembodiments of the invention. The control logic definition 322 for thedefinition module 300 is edited in a control logic editor window 456using a known control logic editor or control logic drawing builder. Thecontrol logic definition 322 includes the part 220 and subparts 202,204, 206. Properties which are fixed, and parameters which are variablesof the properties, for each of the part 220 and sub-parts 202, 204, 206are listed in a part property window 458. Examples of the propertiesdisplayed in the part property window 45 are identifier or “Tag Name”,“Type”, “Rule”, “Tag Comment”. For each property, the default or list ofparameters are provided for selection, user input is checked forvalidity, or a check box is provided for selection appropriately.

The module library window 452, module property file window 454, controllogic editor window 456 and part property window 458 are separate areason the display screen 450. The windows are arranged in a tiled displayfor ease of view and use.

The application module 440 is equivalent to an instance in objectoriented programming. In object oriented programming, an instance isgenerated by instantiating a class module, which applies or uses actualvalues in the class module. In the present invention, the actual valuesare based on user input or input signals received from an input device1200.

The module generation component 412 generates a required number ofapplication modules. In the example for the equipment 210, the requirednumber of application modules 440, 442, 444, 446, 448 are generated orinstantiated for the parts 220, 222, 224, 226, 228 control the equipment210.

The module generation component 412 prepares or generates new definitionmodules 300 for each different status of the equipment 210. For thisfunction, the module generation component 412 starts with a newdefinition module 300. The new definition module 300 has predefineddefault properties in the property file 310 and no information in thecontrol logic definition file 320, document definition file 331. Thereare different types of definition module 300, for example for equipment210 type, part 220 type, sub-part 206 type, function type, manufacturertype or a mixture of manufacturer-function type. The different types ofdefinition module 300 are listed for selection in a method to prepare anew definition module 300. The selection includes an option to prepare anew type of definition module 300. This is based on user instructions inthe form of user input or input signals received from the input device1200.

The module generation component 412 modifies the application module 440for each different status of the equipment 210. The relevant fields inthe property file 310 are updated to identify the modified application440. This is based on user instructions in the form of user input orinput signals received from the input device 1200.

In S618, the module generation component 412 stores generatedinstantiated or modified application modules 440, and generateddefinition modules 300 in the database 430. The database 430 is set upin a same or different memory storage medium as editor tool 400.

The module generation component 412 is activated to perform theconfigured functions based predefined rules such as an input orschedule. Example of a predefined input is a user input, using the inputdevice 1200, to activate the module generation component 412.

The module library 432 has a plurality of definition modules 300according to some embodiments of the invention. The plurality ofdefinition modules 300 is displayed in the module library window 452 ina hierarchy tree structure. This enables easy navigation to locate adesired definition module 300 for view or edit.

Link Generation Component 414

The editor tool 400 includes a link generation component 414. The linkgeneration component 414 is configured to perform one or more functionsdescribed below.

FIG. 6B is a workflow 620 of a function performed by the link generationcomponent 414 according to some embodiments of the invention. The linkgeneration component 414 retrieves each definition module 300 from thedatabase 430 in S622. In S624, for each definition module 300, the linkgeneration component 414 identifies the part 220, the sub-parts 202,204, 206, the control logic definition 322, the application module 440related to the definition module 300. In S626, the link generationcomponent 414 retrieves information of the part 220, the sub-parts 202,204, 206, the control logic definition 322, the application module 440from the database 430 based on the identification in S624. In S628, thelink generation component 414 generates a link 416 to link or bind theretrieved information. The link 416 as shown in FIG. 4B is between theapplication module 440 and definition module 300. In S629, the linkgeneration component 414 stores the generated link 416 to the database430.

A function of the link generation component 414 is to generate a link417 when the application module 440 is assigned to controller 212. FIG.6C is a workflow 630 performed by the link generation component togenerate the link 417. Step S632 provides a list of the generatedapplication module 440, 442, 444, 446, 448 for selection. Step S634provides a list of available controllers 212 213, for selection, to beassigned to the selected application module 440 in S632. In Step S636,the link 417 is generated to link or bind the selected applicationmodule 440 to the controller 212. In Step S638, the link 417 is storedto the database 430. The link generation component 414 to generate thelink 417 is provided as a separate link generation component 414 togenerate the link 416 according to some embodiments of the invention.

Advantageously, the generated link 417 causes the application module 440control logic 206 for the field devices 202, 204 to be executed in thecontroller 212. This is referred to as logical binding and isindependent on the physical connection of the field devices 202, 204with the controller 212. During a maintenance task, the logical bindingis updated independent on the physical connection. Advantageously, auser performing a configuration task or maintenance task for any part220 of the process control system 200 does not need to be concerned withthe physical connection.

The link generation component 414 performs a link modification functionaccording to some embodiments of the invention. The link generationmodule component 414 provides a listing of available options for theretrieved information. For example, the definition module 300 isidentified for the part 220. The link generation module 414 provides alisting of other definition modules which are available options for thepart. In another example, a listing of other field devices, identifiedby identifiers or tag names, which are available options for thesubparts 202, 204. A user makes a selection from the available options.The link generation module component 414, based on the selection,generates an updated link 416. The updated link 416 is stored to thedatabase 430.

FIG. 7B is an example display screen 460, in the editor tool 400, todisplay the generated link 416. Navigation window 462 displays aplurality of group types, such as plant equipment, plant area, plantprocess, equipment vendor, for a user to select the desired equipment210, part 220. In the present example, the user selects to view theequipment 210. A link list window 464 lists identifiers, in the columnlabelled “P&ID Tag Name”, for the equipment 210. In this example, theidentifier is for the controller 212 of each part 220, 222, 224, 226,228. Information for each controller 212 is listed in the correspondingcolumns based on links 416 generated by the link generation component414. The information illustrated in this example are “APM Path”, whichis a storage location for the corresponding application module 440, 442,444, 446, 448; “APM Name” which is the name of the correspondingapplication module 440, 442, 444, 446, 448; “Class” which is thedefinition module 300 for each part; “IO Tag Name” which is theidentifier for the corresponding sub-parts 202, 204. A property window466 (not shown) is included to display properties of a selection on thedisplay screen 460 when the selection has properties.

The navigation window 462, the link list window 464, the property window466 and part property window 458 are separate areas on the displayscreen 460. The windows are arranged in a tiled display for ease of viewand use. The list of available options for the information is providedin an option window or a drop down list 468 (not shown).

The link generation component 414 performs the functions when anapplication module 440 is generated. Alternatively, the link generationcomponent 414 performs configured functions based on a predefined input,schedule or when a change is detected for any information according tosome embodiments of the invention. Example of a predefined input is auser input, using the input device 1200, to activate the link generationcomponent 414. Changes to the information include a selection of analternative available option for a part, subpart of definition module.

Document Layout Configuration Component 418

The editor tool 400 includes a document layout configuration component418. The document layout configuration component 418 is configuredperform one or more functions described below to define a layout 419.The layout 419 is settings or configuration for a plant document 530.The layout 419 includes a listing of the settings, an example of thelisting is a content listing or table of contents for the plant document530. The plant document 530 is generated based on the layout 419.

FIG. 6D is a workflow 640 of a function performed by the document layoutconfiguration component 418 according to some embodiments of theinvention. The document layout configuration component 418 retrieveseach definition module 300 from the database 430 in S642. In S644, foreach definition module 300, the document layout configuration component418 identifies layout information of the document definition file 331.The layout information is contents of the layout file 334, or headers ofdocument definition files 331, document files 332, 336, 338 when alayout file 334 is not defined for the document definition file 331.

In S646, the document layout configuration component 418 arranges, setsor fixes a layout 419, based on the layout information according to apredefined layout sequence or hierarchy. An example of a layout sequenceis layout information for a definition module 300, followed by layoutinformation for application modules 440, 442, 444, 446, 448. An exampleof a hierarchy is document files 332, 334, 336, 338 under the documentdefinition file 331. The document layout configuration component 418receives user input from input device 1200 to arrange the layout 419according to some embodiments of the invention.

In S648, the arranged layout 419 is stored to the database 430.

Alternatively, the document layout configuration component 418determines if a layout file 334 is defined for the document definitionfile 331 in each definition module 300. The document layoutconfiguration component 418 retrieves an application module 440 for thedefinition module 300 when the layout file 334 is defined. Theapplication module 440 is generated based on user input or input signalsreceived from an input device 1200. The application module 440 inheritslayout 419 from the layout information in the layout file 334. Thedocument layout configuration component stores the inherited layout 419in the database 430.

The document layout configuration component 418 has a layoutmodification function according to some embodiments of the invention.The document layout configuration component 418 retrieves a storedlayout 419. The document layout configuration component 418, based onthe retrieved layout 419 and user input received from an input device1200, arranges, sets or fixes a layout 419. This improves the efficiencyof preparing a plant document 530. The layouts 419 are categorized andstored according to type of plant document 530, for example,specification, instruction manual, control logic definitions, accordingto some embodiments of the invention. The information required for thedifferent types of plant document 530 are usually different. Inaddition, different customers for different process plants havedifferent documentation requirements. Advantageously, this improves theefficiency and consistency of documentation. Further, a database ofavailable layouts 419 enables users to maintain a standardizeddocumentation to minimize users creating unnecessary new layouts.

FIG. 7C is an example display screen 470 for the document layoutconfiguration component 418. A layout window 472 displays layoutinformation for a retrieved definition module 300 and an applicationmodule 440 according to a predefined sequence or hierarchy. The layoutinformation is a list of headers or identifiers 474 for documentdefinition files 331, document files 336, 338, 340 when a layout file334 is not defined. In this example, a top level hierarchy of the layoutinformation lists identifier properties of the definition module 300“PID_A01”, the application module 440 “PID_B01”; a subsequent levelhierarchy lists documents 336, 338, 340 “Control Drawing”, “ParameterSetting” “Narrative”, “Applicable list”.

The document layout configuration component 418, includes a selectiontool 476 on the layout window 472 according to some embodiments of theinvention. The selection tool 476 is a drag and drop function torearrange the layout 419 based on the user input. The selection tool 476is a checkbox provided for each header or identifier 474 to be includedor excluded based on the user input.

Plant Document Generation Component 420

The editor tool 400 includes a plant document generation component 420.The plant document generation component 420 is configured to generateplant documents 530 such as specification, instruction manual, controllogic definitions. The plant document generation component 420 retrievesa definition module 300, application module 440, links 416 and layout419 from the database 430. The plant document generation component 420applies the control logic definition 322, links 416,417 and layout 419to generate the plant document 530. The generated plant document 530 isstored in the database 430.

Using an example for explanation, the plant document generationcomponent 420 retrieves for an equipment 210, the stored definitionmodule 300, application modules 440, 442, 444, 446, 448 for the parts220, 222, 224, 226, 228, links 416, 417 and layout 419. The plantdocument generation component 420 generates a plant document 530, basedon the control logic definitions 322, links 416, 417 and layout 419.

FIG. 7D is an example contents table 480 of a plant document 530.Contents list 482 is generated based on the definition module 300 andthe relevant links 416, 417 layout 419. Contents list 484 is generatedbased on the application module 440, the relevant links 416, 417, andlayout 419. Contents list 486 is generated based on the applicationmodule 442 and the relevant links 416, 417 layout 419.

Since the plant document 530 is generated based on control logicdefinitions 322, the plant document 530 is consistent with the controllogic definitions 322. The plant document 530 is automatically generatedby this invention which improves the efficiency and accuracy forgeneration and update of the plant document 530 for any changes in thedesign data 234 of the industrial plant 230 such as process 232, controllogic 206, parameter setting 324, alarm setting 325. The improvedaccuracy increase reliability of the plant document 530 when it is usedto understand the setting or configuration of the industrial plant 230.

Further, a plurality of plant documents 530 for different control logicor different composition of raw materials are conveniently andefficiently generated when the difference is updated in the definitionmodule 300 or application module 440. Significantly less manpower, timeand effort is required to understand the difference and generate plantdocuments 530 when using this invention. Less time and cost are requiredfor preparation, maintenance and update of the plant documents 530.

In an implementation of a process control system 200 for an industrialplant 230, document data 332 is prepared based on specifications of theprocess control system 200. The document data 332 is then translated tocontrol data 510 to be encapsulated in multiple function blocks 205,207. Then tests are done to ensure that the industrial plant 230performs according to specifications. A plurality of plant documents 530is prepared for different aspects of the industrial plant 230, from thedocument data 332 to the test data. Often, information or data isrelated or even duplicated. The present invention generates links 416 sothat related data and plant documents 530 are updated automatically forany change. This improves the efficiency on preparation, maintenance andupdate of process control system 200.

Part Modification Component 422

Test operations are performed during preparation or maintenance ofprocess control system 200. During the test operations, there arechanges in the industrial plant 230 to improve yield from the controllogic 206. Examples of such changes are parameter settings 324 of partequipment 210, sub-parts field devices 202, 204 and any other relevantpart-related information. Besides improving the yield during testoperations, other reasons for the same changes include change inspecifications of the industrial plant 230 and mistakes to be fixed.

The editor tool 400 includes a part modification component 422configured to modify part-related information of part equipment 210,sub-parts field devices 202, 204, such as parameter setting 324. Themodule generation component 412 automatically updates correspondinginformation of the definition module 300 and application module 440 whenthe part modification component 422 has modified the part-relatedinformation. The module generation component 412 is activated to performconfigured functions based predefined rules such as an input orschedule. Example of a predefined input is a user input, using the inputdevice 1200, to activate the module generation component 412.

The editor tool 400 transmits the application module 440 to thegeneration manager 500 to convert the control logic 206 in control logicdefinition 322, alarm definition 326 to logic control data 512. The link417 is also transmitted and converted to link control data 514. Theprocess control system 200 determines the logic control data 512 to beexecuted in the controller 212 to control the process 232 based on thelink control data 514.

Mass Editor Component 424

The editor tool 400 includes a mass editor component 424. The masseditor component 424 updates a parameter change in all related modulesor files. The mass editor component 424 is configured to be activated inany editor or configuration component in the editor tool 400.

In an example the mass editor component 424 is activated in a controllogic editor in the module generation component 412. The mass editorcomponent 424 identifies, from the database 430, all files and moduleswhich are editable by the control logic editor. The mass editorcomponent 424 provides a list of the identified files and modules foruser selection according to some embodiments of the invention.

The identified or selected files and modules are then checked out of thedatabase 430 or locked for a concurrent edit by a user or another tool.This maintains data integrity of the files and modules. The parametersin the checked out files and modules are generated in an output file forview and edit. In some embodiments, the output file is a data grid basedon a predefined data grid format for the control logic editor. The cellsin the data grid are differentiated to editable and read-only cellsaccording to some embodiments of the invention.

An input for a parameter change is received by the mass editor component424. The mass editor component 424 determines the related parameters inthe output file and updates the related parameters accordingly.

In the embodiment when the output file is a data grid, the mass editorcomponent 424 further includes a grid rule component 426. The grid rulecomponent 426 is configured to define a grid rule which has a logicalcondition for a parameter change and a corresponding action to updatethe related parameters in the data grid when the logical condition isfulfilled. An example use of grid rule is to change naming convention oftags for a type of tags starting with “ABC###” to “XYZ###”. The masseditor component 424 uses the defined grid rule to search for tagidentifiers which fulfil the logical condition when the tag identifiersstart with “ABC”. The mass editor component 424 performs a correspondingaction to replace “ABC” with “XYZ” in the searched tag identifiers.

The mass editor component 424 determines if the parameter change andupdates in the related parameters are valid prior to check in or unlockof the identified files and modules.

The defined grid rule is stored to the repository 1300 for re-use byother mass editor components 424. The mass editor component 424 importsa defined rule from the repository for direct use or modification beforeuse according to some embodiments of the invention

The mass editor component 424 improves efficiency, flexibility andreliability of bulk or mass data change such as parameter value updateor naming convention change. In a conventional system for bulk datachange, all the files are listed for filtering or selection, then thedetails in the filtered file are further filtered or selected. Thefiltered data from the details is exported to a spreadsheet such asMicrosoft Excel™ or comma-separated (.CSV) files to effect the changebefore imported to replace the exported files. There is no validitycheck for the change which may result in data failures when the importedfiles are read. Resources are lost to determine and rectify the cause ofthe data failures. Further, when the filtered data is exported, multipleexports can be done simultaneously by a different user or another tool.The data integrity may be lacking when changes may not have beeneffected on a desired version of the data.

Method of Invention

FIG. 8A is a workflow 800 for using the editor tool 400 to set up orconfigure a process control system 200 based on specifications 234 forequipment 210 selected in step S802. Step S804 identifies a definitionmodule 301 for the equipment 210. The definition module 301 isidentified to be a definition module 300 without nesting levels or adefinition module 301 with multiple nesting levels. The definitionmodule 301 is prepared using the module generation component 412 orsearched from the database 430 using a search function in the editortool 400.

Step S806 modifies the definition module 301 according to thespecifications 234. Property file 310, control logic definition file320, document definition file 331 in the definition module 301 aremodified based on the specifications 234.

Step S808 determines if new definition modules 300 are required andadded when required. Obsolete modules 300 are determined and are deletedwhen the definition module 301 includes multiple definition modules 300.Obsolete definition modules 300 are those which are not applicable orvalid based on the specifications 234.

Step S810 determines whether any changes are made to the nested modules302, 304, 306 when the definition module 301 includes nested modules302, 304, 306. Steps S806 and S808 are repeated for each nested module302, 304, 306 which is changed based on specifications 234.

Step S812 stores the updated definition module 301 according to someembodiments of the invention. Step S812 generates correspondingapplication modules 440, 442, 444, 446, 448 according to someembodiments of the invention. Then at least one of the updateddefinition module 301 and its corresponding application modules 440,442, 444, 446, 448 are stored to the database 430.

In Step 820, the editor tool 400 retrieves the application modules 440,442, 444, 446, 448 from the database 430 and sends the applicationmodules 440, 442, 444, 446, 448 to a generation manager 700. Thegeneration manager 700 prepares control data 510 based on theapplication modules 440, 442, 444, 446, 448 for the process controlsystem 200. In particular, the control data 510 is prepared for thefunction blocks 205,207 of the process control system.

In Step 830, the editor tool 400, based on user input from the inputdevice 1200 the plant document generation component 420, generates plantdocuments 530 from the application modules 440.

FIG. 8B is an example workflow 850 for using the mass editor component424 according to some embodiments of the invention.

The mass editor component 424 is activated in a control logic editor inthe module generation component 412 in Step S852. The mass editorcomponent 424 identifies, from the database 430, all files and moduleswhich is editable by the control logic editor. The mass editor component424 provides a list of the identified files and modules for userselection according to some embodiments of the invention.

Step S854, the identified or selected files and modules are checked outof the database 430. The parameters in the checked out files and modulesare generated in a data grid based on a predefined data grid format forthe control logic editor. The cells in the data grid are differentiatedto editable and read-only cells according to some embodiments of theinvention.

In Step S856, an input for a parameter change is received by the masseditor component 424. The mass editor component 424 determines therelated parameters in the data grid and updates the related parametersaccordingly. Step S857 is an alternative step to import or define a gridrule with a logical condition and a corresponding action when thelogical condition is fulfilled.

In Step S858, the mass editor component 424 determines if the parameterchange and updates in the related parameters are valid prior to check inor unlock of the identified files and modules. The check in or unlock ofidentified files is in Step S859.

Advantageously, this invention improves ease of preparing control datafor any process control system 200 based from specifications 234. Inaddition, plant documents 530 are generated with less effort when thedocument definition files 331, attachment files 340 are updated based onthe specifications 234. This reduces manpower costs for preparing,generating control data 510 and plant documents 530 for eachmodification, change or maintenance of the industrial plant 230.Further, the database 430 is available to be used for differentindustrial plants 230, thus improving the efficiency to modify, set upor configure a process control system 200 for a new process 232 or newindustrial plant 230.

In a situation where control logic definition 322, is confidential, theconfidential application module 440 is not made available for use indifferent industrial plant 230. However, the definition module 300 isstill available or vice versa for the application module 440 when thedefinition module 300 is confidential.

System Configuration

FIG. 9 is a system configuration 900 for process control according tosome embodiments of the invention. The field devices 202, 204 areconnected to a field network 106. The field devices 202, 204 areconnected through input-output (I/O) units to controllers 212 which arein a control network 110. The editor tool 400 is configured at thecontrol network 110 level to prepare definition module 300 as describedabove. The control network 110 is suitable for process control systemsthat incorporates general communication functions and enables highlyreliable, real-time, and stable communications. An example of thecontrol network is Vnet/IP which uses the IP Internet protocol forgeneral-purpose communications and conforms to CPF-10 of the real-timeEthernet (RTE) communication profile defined in IEC 61784-2.

FIG. 10 is a block diagram for a system 1000 configuration of thepresent invention. The system 1000 includes a processor 1100 which ispart of a computer. The processor 1100 communicates with input device1200, storage 1300, display 1400, output or transmission device 1500.The input device 1200, storage 1300, display 1400, output ortransmission device 1500 are in the same or separate computer as theprocessor according to some embodiments of the invention.

The editor tool 400 and the converter tool 500 are implemented in one ormore processors 1100.

Input device 1200 is an interface device to receive user input, inputimport from alternative source/third parties. Examples of input device1200 are keyboard, pointing device such as a mouse, touch-sensitivedisplay interface.

Database 430 is in storage or repository 1300 is a memory storage mediumsuch as Random Access Memory, Read Only Memory or Hard Disk Drive for.The memory storage medium stores part library 431 which includesequipment 210, parts 220, 222, 224, 226, 228, sub-parts field devices202, 204, control logic 206, network device 208; module library 432which includes the definition modules 300, 301, 302, 304, 306,derivative application modules 440, 442, 444, 446, 448; link library 434links 416, 417; layout library 436 for layouts 419; document library 438for plant documents 530 and related information described above.

The database 430 has a plurality of memory components to store theinformation by type. Advantageously, this improves the ease ofconfiguring the components 410, 412, 414, 418, 420, 422 in the editortool 400 to retrieve the required information. Configuring thecomponents 410, 412, 414, 418, 420, 422 include setting them to performthe functions described above. Further, the stored information issuitable to be retrieved for any other purpose such as an external tool.

The invention is not limited to the described embodiments. The inventionis intended to cover alternatives, modifications and equivalents, whichmay be included within the spirit and scope of the invention as definedby appended claims. Furthermore, it will be obvious to one of ordinaryskill of the art that the present invention may be practiced without thespecific details. The specific details have been included to provide athorough understanding of the invention. Finally, well known methods,procedures, components, and features have not been described in detailas not to unnecessarily obscure aspects of the present invention.

Further embodiments of the inventions are described below.

A configuration system for a process control system configured toperform process control. The configuration system includes, not limitedto, a) a definition module, which is stored in a memory, for a part ofan industrial plant based on design data. The definition moduleincludes, not limited to, a-1) a control logic definition fileconfigured to define a control logic for the part, and a-2) a datadefinition file configured to define data relating to the definedcontrol logic.

The configuration system of claim 1, further includes b) an editorconfigured to perform at least one of generation and update of at leastone of the control logic definition file and the data definition file,wherein the editor is implemented by one or more processors.

The configuration system in claim 2 further includes c) a converterconfigured to convert the control logic definition into control data forthe process control system, wherein the converter is implemented by oneor more processors.

The configuration system, wherein the definition module further includesa-3) a property file configured to store a module property for the part.

The configuration system, wherein the part includes one input parameterand one output parameter.

The configuration system is further configured to communicate with adata source which includes a parameter for the part. The control logiccomprises a control logic parameter. The data definition file comprisesa rule file configured to define a rule comprising a condition and anaction for setting the parameter to the control logic parameter, basedon the defined condition.

The configuration system, wherein the data definition file comprises adocument file configured to define control logic specifications data fordocumentation.

The configuration system, wherein the part includes a plurality ofsub-parts, and the definition module comprises a plurality of sub-partdefinition modules for the sub-parts.

The configuration system wherein the control logic definition file isfurther configured to define at least one tuning parameter.

Another aspect of the invention is a configuration system for a processcontrol system configured to perform process control, the configurationsystem includes, not limited to, a) an editor configured to generate anapplication module, the application module includes, not limited to a-1)a control logic definition file configured to define a control logic forthe part, and a-2) a data definition file configured to define datarelating to the defined control logic. The editor is implemented by oneor more processors.

The configuration system is configured to communicate with a serverhaving a data source. The editor is further configured to retrieve adefinition module which includes a first control logic and design dataand retrieve, from the data source in the server, part-related data. Theapplication module is as an instance of the definition module based onthe part-related data. The control logic definition file has aninstantiated second control logic based on the part-related data, andthe data definition file has an instantiated data relating to the secondcontrol logic.

The configuration system further includes b) a converter configured toconvert the application module to control logic data for the processcontrol system. The converter is implemented by one or more processors.

The configuration system wherein the part comprises one input parameterand one output parameter.

The configuration system is further configured to communicate with adata source includes a part source parameter for the part, wherein thecontrol logic includes a control logic parameter. The data definitionfile includes a rule file configured to define a rule comprising acondition and an action for setting the part source parameter to thecontrol logic parameter, based on the defined condition.

The configuration system wherein the data definition file includes adocument file configured to define control logic specifications data fordocumentation.

The configuration system wherein the control logic definition file isfurther configured to define at least one tuning parameter.

In yet another aspect of the invention is a non-transitory computerreadable medium that stores a computer program to be executed by aconfiguration system to perform a configuration method performed by aconfiguration system for a process control system configured to performprocess control. The configuration method includes, not limited to, a)storing, in a memory, a definition module for the part of the industrialplant. The definition module includes, not limited to a-1) a controllogic definition file configured to define a control logic for the part,and a-2) a data definition file configured to define data relating tothe defined control logic; and b) updating the definition module.

The method, in the medium, further includes c) performing, using aneditor, at least one of generation and update of at least one of thecontrol logic definition file and the data definition file. The editoris implemented by one or more processors.

The method, in the medium, further includes d) converting, using aconverter, the definition module to control logic data for the processcontrol system. The converter is implemented by one or more processors.

In another aspect of the invention, a process control system for use ina process plant having a user interface and one or more processcontrollers. The process control system includes, not limited to, a) anapplication module instantiated from a definition module, b) a converterconfigured to convert the control logic definition into control data,and c) a controller adapted to execute the control data on the one ormore process controllers to implement process control activities withinthe process plant. The application module, includes, not limited to a-1)a control logic definition file configured to define a control logic fora part of the process plant, and a-2) a data definition file configuredto define data relating to the defined control logic. The editor and theconverter are implemented by one or more processors.

What is claimed is:
 1. A configuration system for a process controlsystem configured to perform process control, the configuration systemcomprising: a definition module, stored in a database, for a part of anindustrial plant based on design data, the part comprising at least oneof plant equipment and field devices of the industrial plant, the partincluding a plurality of sub-parts, and the definition module comprisinga plurality of sub-part definition modules for the sub-parts, thedefinition module comprising: a control logic definition file configuredto define a control logic for the part, wherein the control logiccomprises a control logic parameter, and the control logic is to beconverted into control data for execution in a field controllerconfigured to control the at least one of plant equipment and fielddevices in accordance with the design data; and a data definition fileconfigured to define data relating to the defined control logic, whereinthe data definition file comprises a document file configured to definecontrol logic specifications data for documentation; a rule fileconfigured to define a rule comprising a condition and an action forsetting the parameter to the control logic parameter, based on thedefined condition; and a property file configured to store a moduleproperty for the part; an application module, stored in the database;and a computation control component configured to perform at least oneof generation and modification of the control logic definition file andthe data definition file to perform at least one of generation andmodification of the application module, based on the control logicdefinition file, the data definition file, and the property file of thedefinition module, wherein the computation control component comprises:a module generation component configured to generate the definitionmodules for each different status of equipment; and a link generationcomponent configured to: identify, for each of the definition modules,the part, the sub-parts, the control logic definition, and theapplication module related to the definition module; retrieve, from thedatabase, the part, the sub-parts, the control logic definition, and theapplication module related to the definition module; generate a linkbetween the application module and the definition module and store thelink into the database; and generate a link between the applicationmodule and a controller when the application module is assigned to thecontroller to logically bind the at least one plant equipment and thefield devices of the industrial plant to the controller, and to placethe at least one of the plant equipment and the field devices of theindustrial plant into an independent state on the physical connectionwith the controller.
 2. The configuration system in claim 1 furthercomprising: a converter configured to convert the control logicdefinition into control data for the process control system, wherein theconverter is implemented by one or more processors.
 3. The configurationsystem in claim 1 wherein the part comprises one input parameter and oneoutput parameter.
 4. The configuration system in claim 1, wherein thesystem is further configured to communicate with a data sourcecomprising a parameter for the part.
 5. The configuration system inclaim 1, wherein the control logic definition file is further configuredto define at least one tuning parameter.
 6. A configuration system for aprocess control system configured to perform process control, theconfiguration system comprising: an editor configured to perform atleast one of generation and modification of an application module, theapplication module comprising: a control logic definition fileconfigured to define a control logic for a part of an industrial plantbased on design data, wherein the part comprises at least one of plantequipment and field devices of the industrial plant, and wherein thecontrol logic is to be converted into control data for execution in afield controller configured to control the at least one of plantequipment and field devices in accordance with the design data; and adata definition file configured to define data relating to the definedcontrol logic, wherein the data definition file comprises a documentfile configured to define control logics specifications data fordocumentation, a rule file configured to define a rule comprising acondition and an action for setting the parameter to the control logicparameter, based on the defined condition, and a property fileconfigured to store a module property for the part; and an applicationmodule, stored in the database; and a computation control componentconfigured to perform at least one of generation and modification of thecontrol logic definition file and the data definition file to perform atleast one of generation and modification of the application module,based on the control logic definition file, the data definition file,and the property file of the application module, wherein the computationcontrol component comprises: a module generation component configured togenerate the definition modules for each different status of equipment;and a link generation component configured to: identify, for each of thedefinition modules, the part, the sub-parts, the control logicdefinition, and the application module related to the definition module;retrieve, from the database, the part, the sub-parts, the control logicdefinition, and the application module related to the definition module;generate a link between the application module and the definition moduleand store the link into the database; and generate a link between theapplication module and a controller when the application module isassigned to the controller to logically bind the at least one plantequipment and the field devices of the industrial plant to thecontroller, and to place the at least one of the plant equipment and thefield devices of the industrial plant into an independent state on thephysical connection with the controller, and wherein the editor isimplemented by one or more processors.
 7. The configuration system inclaim 6 wherein the configuration system is configured to communicatewith a server having a data source, wherein the editor is furtherconfigured to: retrieve a definition module comprising a first controllogic and design data; and retrieve, from the data source in the server,part-related data, wherein the application module is as an instance ofthe definition module based on the part-related data, and wherein thecontrol logic definition file having an instantiated second controllogic based on the part-related data, the data definition file having aninstantiated data relating to the second control logic.
 8. Theconfiguration system in claim 6 further comprising: a converterconfigured to convert the application module to control logic data forthe process control system, wherein the converter is implemented by oneor more processors.
 9. The configuration system in claim 6 wherein thepart comprises one input parameter and one output parameter.
 10. Theconfiguration system in claim 6, wherein the system is furtherconfigured to communicate with a data source comprising a part sourceparameter for the part.
 11. The configuration system in claim 6, whereinthe control logic definition file is further configured to define atleast one tuning parameter.
 12. A non-transitory computer readablemedium that stores a computer program to be executed by a configurationsystem to perform a configuration method performed by a configurationsystem for a process control system configured to perform processcontrol, the configuration method comprising: storing, in a memory, adefinition module for a part of an industrial plant based on designdata, wherein the part comprises at least one of plant equipment andfield devices of the industrial plant, the definition module comprising:a control logic definition file configured to define a control logic forthe part wherein the control logic is to be converted into control datafor execution in a field controller configured to control the at leastone of plant equipment and field devices in accordance with the designdata, a data definition file configured to define data relating to thedefined control logic, wherein the control logic comprises a controllogic parameter, and the control logic is to be converted into controldata for execution in a field controller configured to control the atleast one of plant equipment and field devices in accordance with thedesign data; and a property file configured to store a module propertyfor the part updating the definition module; storing, in the memory, anapplication module; performing at least one of generation andmodification of the control logic definition file and the datadefinition file to perform at least one of generation and modificationof the application module, based on the control logic definition file,the data definition file, and the property file of the definitionmodule; generating the definition modules for each different status ofequipment; identifying, for each of the definition modules, the part,the sub-parts, the control logic definition, and the application modulerelated to the definition module; retrieving, from the database, thepart, the sub-parts, the control logic definition, and the applicationmodule related to the definition module; generating a link between theapplication module and the definition module; storing the link into thedatabase; and generating a link between the application module and acontroller when the application module is assigned to the controller tologically bind the at least one plant equipment and the field devices ofthe industrial plant to the controller, and to place the at least one ofthe plant equipment and the field devices of the industrial plant intoan independent state on the physical connection with the controller. 13.The non-transitory computer readable medium in claim 12 wherein themethod further comprises: performing, using an editor, at least one ofgeneration and update of at least one of the control logic definitionfile and the data definition file, wherein the editor is implemented byone or more processors.
 14. The non-transitory computer readable mediumin claim 12 wherein the method further comprises: converting, using aconverter, the definition module to control logic data for the processcontrol system, wherein the converter is implemented by one or moreprocessors.
 15. A process control system for use in a process planthaving a user interface and one or more process controllers, the processcontrol system comprising: an application module instantiated from adefinition module, the application module comprising: a control logicdefinition file configured to define a control logic for a part of theprocess plant wherein the part comprises at least one of plant equipmentand field devices of the process plant, and wherein the control logic isto be converted into control data for execution in a field controllerconfigured to control the at least one of plant equipment and fielddevices in accordance with the design data, and a data definition fileconfigured to define data relating to the defined control logic, whereinthe data definition file comprises a document file configured to definecontrol logic specifications data for documentation, and a rule fileconfigured to define a rule comprising a condition and an action forsetting the parameter to the control logic parameter, based on thedefined condition; and a property file configured to store a moduleproperty for the part; a converter configured to convert the controllogic definition into the control data; and a controller adapted toexecute the control data on the one or more process controllers toimplement process control activities within the process plant, thecontroller adapted to perform at least one of generation andmodification of the control logic definition file and the datadefinition file to perform at least one of generation and modificationof the application module, based on the control logic definition file,the data definition file, and the property file of the applicationmodule, wherein the computation control component comprises: a modulegeneration component configured to generate the definition modules foreach different status of equipment; and a link generation componentconfigure to: identify, for each of the definition modules, the part,the sub-parts, the control logic definition, and the application modulerelated to the definition module; retrieve, from the database, the part,the sub-parts, the control logic definition, and the application modulerelated to the definition module; generate a link between theapplication module and the definition module and store the link into thedatabase; and generate a link between the application module and acontroller when the application module is assigned to the controller tologically bind the at least one plant equipment and the field devices ofthe industrial plant to the controller, and to place the at least one ofthe plant equipment and the field devices of the industrial plant intoan independent state on the physical connection with the controllerwherein the editor and the converter are implemented by one or moreprocessors.